86302102

INDEX
The following are registered trademarks of

Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, RideGuide and MMPP.
GASOLINE ENGINES 496 MAG BRAVO

MODELS INSTALLATION MANUAL
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owner’s Future Use.
NOTICE to COMMISSIONING DEALER

Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . 2 Installing Transom Assembly . . . . . . . . . . . . . . 34
Notice to Boat Manufacturer/Installer . . . . 2 Installing Inner Transom Plate . . . . . . . . . . 36
Bravo Three Notice: Installing Power Trim Pump . . . . . . . . . . . . 37
Trim-In Limit Pin Insert . . . . . . . . . . . . . . . . 3 Installing Steering System . . . . . . . . . . . . . 38
496 MAG And 496 MAG HO Connecting Speedometer Pickup . . . . . . . 42
Application Recommendations . . . . . . . . . 4 Connecting Sterndrive Unit Gear Lube
Multiple Sterndrive Steering Monitor Hose To Gimbal Housing . . . . . . . 43
Tie Bar Arrangements . . . . . . . . . . . . . . . . 5 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 44
Quicksilver Products . . . . . . . . . . . . . . . . . . 6 Engine Preparation . . . . . . . . . . . . . . . . . . . 44
Lubricants / Sealants / Adhesives . . . . . . . 7 Transom Preparation . . . . . . . . . . . . . . . . . . 45
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installing Engine/Alignment . . . . . . . . . . . . 46
Torque Specifications . . . . . . . . . . . . . . . . . 7 Engine Connections . . . . . . . . . . . . . . . . . . . . . 51
Serial Number Decal Placement . . . . . . . . 8 Audio Warning System Connection . . . . . 57
Corrosion Protection . . . . . . . . . . . . . . . . . . 8 Shift Cable Installation and Adjustments . . . . 59
Anti-fouling Paint . . . . . . . . . . . . . . . . . . . . . 9 Installing Sterndrive Unit Shift Cable . . . . 59
Installation Requirements . . . . . . . . . . . . . . . . 10 Troubleshooting Shift Problems . . . . . . . . . 63
Transom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Throttle Cable Installation and Adjustment . . 64
Engine Bed . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Sterndrive Unit Installation . . . . . . . . . . . . . . . . 65
Engine Compartment . . . . . . . . . . . . . . . . . . 11 Predelivery Preparation . . . . . . . . . . . . . . . . . . 73
Exhaust System . . . . . . . . . . . . . . . . . . . . . . 14 Battery Connection . . . . . . . . . . . . . . . . . . . 73
Fuel Delivery System . . . . . . . . . . . . . . . . . . 19 Power Trim Pump . . . . . . . . . . . . . . . . . . . . 73
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Trim Position Sender Adjustment . . . . . . . 74
EFI Electrical System Precautions . . . . . . 23 Power Steering Fluid . . . . . . . . . . . . . . . . . . 77
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . 24 Propeller Installation (Bravo One and Two) 77
Power Trim Control . . . . . . . . . . . . . . . . . . . 24 Propeller Installation (Bravo Three) . . . . . 79
Power Trim Pump Location . . . . . . . . . . . . 24 Test Running Engine . . . . . . . . . . . . . . . . . . 80
Propeller Selection . . . . . . . . . . . . . . . . . . . . 25 Boat In The Water Tests . . . . . . . . . . . . . . . 82
Seawater Connections . . . . . . . . . . . . . . . . 26 Cold Weather or Extended Storage
Hot Water Heater . . . . . . . . . . . . . . . . . . . . . 27 Draining Instructions . . . . . . . . . . . . . . . . . . . . 83
Throttle/Shift Remote Control and Cables 28 Coolant And Water Flow Diagrams . . . . . . . . 88
Steering Helm and Cable . . . . . . . . . . . . . . 28 Power Trim System Wiring Diagram . . . . . . . 90
Transom Cutout . . . . . . . . . . . . . . . . . . . . . . . . . 30 Quicksilver Instrumentation Wiring Diagrams 92
Finding Crankshaft Vertical Centerline . . . 31 MCM Gasoline Engine . . . . . . . . . . . . . . . . 92
Finding Crankshaft Horizontal Centerline 32 MerCathode System Wiring Diagram . . . . . . 94
Checking Transom Thickness . . . . . . . . . . . . . 34 Predelivery Inspection . . . . . . . . . . . . . . . . . . . 96
90-863021002 JANUARY 2001 Printed in U.S.A. -  2001, Mercury Marine Page 1 of 96

GASOLINE ENGINES 496 MAG BRAVO MODELS
General Information
Notice to Boat Manufacturer/Installer
Throughout this publication, Warnings and Cautions (accompanied by the International
Hazard Symbol ! ) are used to alert the manufacturer or installer to special instructions
concerning a particular service or operation that may be hazardous if performed incorrectly
or carelessly. –– Observe Them Carefully!
These Safety Alerts, alone, cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
WARNING
Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
IMPORTANT: Indicates information or instructions that are necessary for proper
installation and/or operation.
NOTE: Refer to the Mercury MerCruiser Product Applications Manual - Gasoline Sterndrive
Models for application recommendations.
This installation manual has been written and published by Mercury Marine to aid the boat
manufacturer (OEM) in the installation of the products described herein.
It is assumed that these personnel are familiar with marine product installation.
Furthermore, it is assumed that they are familiar with, if not trained in, the recommended
installation procedures of Mercury MerCruiser product.
We could not possibly know of or advise the marine trade of all conceivable installations and
of the possible hazards and/or results of each installation. Therefore, the OEM is
responsible for any installation that does not fulfil the requirements of this manual.
It is the responsibility of the boat manufacturer to select the appropriate engine/transom/
drive package (including the correct gear ratio and propeller) for a given boat. Mercury rec-
ommends that any new or unique hull/power package combination be thoroughly water
tested prior to sale, to verify that the boat performs as desired, and that the engine runs in
the appropriate rpm range.
It is recommended that a Mercury Marine Sales Application Engineer (SAE) be contacted
for assistance.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at time of publication. As required, revisions to this
manual will be sent to all OEM boat companies.
Page 2 of 96
Bravo Three Notice: Trim-In Limit Pin Insert

NOTE: Bravo One, Two and Three Models are equipped with a Trim-In Limit Pin Insert.
It has been brought to our attention that some boats (predominantly deep-Vee heavy boats)
will roll up on their side under certain, specific, operating conditions. The roll can be either
to port or starboard and may be experienced while moving straight ahead, or while making
a turn. The roll occurs most frequently at or near maximum speed, with the drive unit
trimmed at or near full trim-in. While the boat will not roll completely over, the roll may be
sufficient to unseat the operator or passengers, and thereby create an unsafe situation.
The roll is caused by stern-lift created from excessive drive unit trim-in. Under these extreme
stern-lift / bow-down conditions instability can be created which may cause the boat to roll.
Weight distribution to the stern can reduce stern-lift and, in some circumstances, help to
control the condition. Weight distribution in the bow, port or starboard, may worsen the
condition.
The Trim-In Limit Pin Insert reduces stern-lift by preventing the drive unit from reaching the
last few degrees of full trim under. While this device should reduce the rolling tendency, it
may not eliminate the tendency entirely. The need for this Trim-In Limit Pin, and its effective-
ness, can only be determined through boat testing and is ultimately the responsibility of the
boat manufacturer.
WARNING
It is recommended that only qualified personnel adjust the Trim-In Limit Pin Insert.
Boat must be water tested after adjusting or removing the device to ensure that the
modified trim-in range does not cause the boat to exhibit an undesirable boat handl-
ing characteristic if the drive unit is trimmed In at higher speeds. Increased trim-In
range may cause handling problems on some boats which could result in personal
injury.
Page 3 of 96
496 MAG And 496 MAG HO Application Recommendations

BOAT TYPES
The 496 MAG And 496 MAG HO models are recommended for use in most sport boat
applications with the exception of the following:
• Bravo applications which require that the sterndrive unit be mounted more than 3 in.
(75 mm) above the standard “X” dimension (i.e., catamarans, certain stepped bottom
boats). For those applications, we recommend our Performance Product models with
a Super Speedmaster sterndrive unit which are designed specifically for surfaced
propeller operation.
• Applications which require other than standard Quicksilver propellers to get the boat up
on plane or to keep the propeller from ventilating when up on plane.
• Boats that require that the engine be run above 3200 rpm to keep them on plane.
• Racing applications or other highly abusive applications where the boat and the
sterndrive units will come out of the water frequently. These, again, are applications
where we recommend our Performance Product models with Super Speedmaster
sterndrive units.
STEERING
Mercury MerCruiser power packages come standard with Mercury MerCruiser’s internal
power steering. This durable system provides precise effortless steering control and is
recommended for most sport boat applications. On certain applications, however, Mercury
MerCruiser recommends the use of an external power steering system where the power
steering cylinders connect directly to the sterndrive unit on the outside of the boat. This
arrangement gives additional support for even tighter, more firm steering control, and is
recommended for the following applications:
• High speed single or twin engine applications and/or boats with unusual handling
characteristics.
NOTE: It is virtually impossible to give a specific recommendation as to when external
power steering should be used, as this varies from boat design to boat design. Mercury
MerCruiser recommends using external power steering on boats which operate in excess
of 70 MPH. There are boats which operate at 60 MPH that would benefit from the use of
external power steering. Because of the many variables involved, the final decision as to
whether or not external power steering is required rests with the boat manufacturer and
must be made after a thorough test and evaluation of each specific boat. If there is any
question whether or not external power steering is necessary, Mercury MerCruiser
recommends that it be installed.
• Any Hi-Performance sport boat powered by three or more engines.
• Offshore boats or other applications where the boat and sterndrive units may come out
of the water occasionally.
• All III SSM and V SSM High Performance Sterndrive applications.
External power steering systems are generally either mechanical cable actuated or
hydraulic actuated. If cable actuation is selected, combining dual steering cables with an
internal control valve kit (P/N 89645A35) will provide an even tighter feel (less steering
backlash). This kit cannot be used with hydraulic actuation.
Page 4 of 96
External power steering and hydraulic helm systems can be obtained from the following
after market suppliers:
Latham Marine, Inc.

280 S.W. 32nd Court
Ft. Lauderdale, FL 33315
Phone: (305) 462-3055
Fax: (305) 462-3081
Mayfair Marine Machine

12890 N. W. 30th Avenue
Opalocka, FL 33054
Phone: (305) 681-1815
On dual or triple engine high speed applications, Mercury MerCruiser recommends the use
of a Quicksilver Priority Valve Kit (P/N 79691A4). This kit allows two power steering pumps
to be used and helps to ensure that power assist will be maintained if one engine or power
steering pump should stop functioning.
ENGINE MOUNTS
NOTE: On offshore boats or boats which will be used in rough water areas, Mercury
MerCruiser recommends the use of a solid plate engine mount.
Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives it is important to consider which of several possible steering sys-
tems should be selected.
CAUTION
Failure to observe the recommended Tie Bar Arrangements as presented in this
section could result in serious damage to the steering and/or trim system compo-
nents. This damage could adversely affect control of the boat.
INTERNAL TIE BAR ONLY
At the lower end of the performance spectrum (boats not capable of speeds in excess of
60 MPH) the basic internal tie bar is recommended. It connects the slave sterndrive to the
sterndrive that is directly connected to the factory power steering output. This internal tie
bar is available in a variety of lengths from the sterndrive manufacturer.
INTERNAL AND EXTERNAL TIE BAR
As a boat moves into a moderate performance range (60-70 MPH) or for a reduction in steer-
ing backlash, an external tie bar should be added. External tie bars are usually designed
to attach at the aft power trim cylinder bosses which is an excellent location because of its
proximity to the propeller. HOWEVER, because of the potential overstress that can occur
if one drive is trimmed much differently than the other, a dual trim control kit (Part Number
90362A3) should be installed so as to limit this potential tilt differential to about 20°.
Page 5 of 96
EXTERNAL POWER STEERING
When boat speeds move past 70 MPH or if additional steering backlash reduction is desired,
external power steering is recommended. This normally will include an external tie bar
mounted at the same general location of the power steering cylinders which are generally
attached at the top of the sterndrive’s drive shaft housing. With this steering system, no inter-
nal tie bar should be used. These steering cylinders can be attached either inboard (be-
tween) or outboard of the sterndrives.
EXTERNAL POWER STEERING WITH LOW EXTERNAL TIE BAR
For the fastest boats (over 80 MPH) or for the ultimate in steering backlash reduction, use
external power steering, BUT (where mechanically possible) with the external tie bar
mounted at the trim cylinder boss location (as previously described in Internal and External
Tie Bar. This system does not use an internal tie bar.
Mercury Marine does not recommend the use of an external tie bar ONLY (no internal tie
bar) when using the internal power steering system. This can cause excessive loads on the
steering components on the drive connected to the internal power steering system. These
increased loads can damage the steering components, resulting in increased play in the
steering of the boat.
Quicksilver Products
ACCESSORIES
Quicksilver remote controls, steering systems, propellers and other accessories are
available for this product. Refer to Mercury Precision Parts/Quicksilver Accessories Guide
for complete listing.
This Guide is available from:
Attn: Parts Department

Mercury Marine
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Outside of U.S.A., order through Distribution Center, or Distributor.
Page 6 of 96
Lubricants / Sealants / Adhesives

Description Part Number
Engine Coupler Spline Grease 92-816391A4
2-4-C Marine Lubricant With Teflon 92-825407A3
U-Joint and Gimbal Bearing Grease 92-828052A2
Special Lubricant 101 92-13872A1
Liquid Neoprene 92-25711-2
Power Trim and Steering Fluid 92-90100A12
Dexron III - Automatic Transmission Fluid Obtain Locally
Perfect Seal 92-34227-1
High Performance Gear Lube 92-802854A1
Tools
Transom Drilling Fixture 91-43693A2
Engine Alignment Tool 91-805475A1
Shift Cable Adjustment Tool 91-12427
Engine Mount Drilling Fixture 91-806794A1
Torque Specifications
Torque
Description
lb-in. lb-ft Nm
Sterndrive Unit Gear Lube Monitor - 90°
80 9
Hose Barb Fitting
Speedometer Pickup Barb Fitting 13 1.5
Exhaust Pipe or Block-off Plate 23 31
Power Steering Hydraulic Hose Fittings 23 31
Power Trim Pump Hose Fittings 125 14
Propeller Nut (Bravo One and Two) 1 55 75
Front 100 136
Propeller Nuts (Bravo Three)1
Rear 60 81
Rear Engine Mounts 38 51
Steering Cable Coupler Nut 35 47
Steering System (Pivot Bolts) 25 34
Sterndrive Unit Fasteners 50 68
Transom Assembly Fasteners 23 31
Seawater Pickup Fitting 45 5
Power Trim Cylinder Fasteners Tighten securely.
Finger tight + 1-3/4 to 2-1/4 turns with a
Fuel Line Fitting
wrench. DO NOT overtighten.
1 Amount specified is MINIMUM.
Page 7 of 96
Serial Number Decal Placement

There are three sets of engine, transom assembly and sterndrive serial number decal strips
provided with each power package. One set should be used for each of the following:
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance and Warranty Manual identification page.
Affix engine serial number decal to specification / serial number decal in position shown.
a
77639
a - Specification/Serial Number Decal
Corrosion Protection
Mercury MerCruiser power packages are equipped with anodes, to help protect them from
galvanic corrosion under moderate conditions. However, for severe conditions, or if using
a stainless steel propeller, it is recommended that a Quicksilver Anti-Corrosion Anode Kit
and/or a MerCathode System be installed (some models have a MerCathode System as
standard equipment). A MerCathode Monitor also is available to allow the operator to check
the operation of the MerCathode System with the push of a button. (Refer to Quicksilver Ac-
cessories Guide for part numbers.)
Boats which are connected to AC shore power, require additional protection to prevent de-
structive low voltage galvanic currents from passing through the shore power ground wire.
A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while
still providing a path to ground for dangerous fault (shock) currents. (Refer to Quicksilver
Accessories Guide for part number.)
IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode
System and anodes may be unable to handle the increased galvanic corrosion
potential.
Page 8 of 96
Anti-fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of anti-
fouling paint will not be covered by the limited warranty.
Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and
boat transom but you must observe the following precautions:
IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and
anode, as this will render them ineffective as galvanic corrosion inhibitors.
IMPORTANT: If anti-fouling protection is required for boat hull or boat transom, cop-
per or tin base paints, if not prohibited by law, can be used. If using copper or tin
based anti-fouling paints, observe the following:
• Avoid an electrical interconnection between the Mercury MerCruiser Product,
Anodic Blocks, or MerCathode System and the paint by allowing a minimum of
1-1/2 in. (40 mm) UNPAINTED area on transom of the boat around these items.
b
71176
a - Painted Boat Transom

b - Minimum 1 1/2 in (40 mm) UNPAINTED Area Around Transom Assembly
NOTE: Drive unit and transom assembly can be painted with a good quality marine paint
or an anti-fouling paint that DOES NOT contain copper, tin, or any other material that could
conduct electrical current. Do not paint drain holes, anodes, MerCathode system or items
specified by boat manufacturer.
Page 9 of 96
Installation Requirements
Transom
a
f
c e e
22033
b
d 22170
a - Transom Thickness - 2 In. (51mm) Minimum To 2-1/4 In.(57mm) Maximum

b - Inner Surface Of Transom Must Be Parallel Within 1/8 In. (3mm) In Area
Covered By Transom Plate (E) And Remain Within Transom Thickness Limits.
c - Outer Surface Of Transom Must Be Parallel Within 1/16 In. (2 mm) In Area
Covered By Transom Plate (E) And Remain Within Transom Thickness Limits.
d - Remove Keel (If Equipped) 4 Ft. (1.2m) Forward To Transom
e - Transom Plate Covers 8 In. (203 mm) To Either Side Of The Vertical Centerline
f - Transom Angle - 10 Degrees To 16 Degrees
Engine Bed
Distance between starboard and port engine mount is 22-1/2 in. (572 mm). Engine bed must
position engine so that a minimum of 1/4 in. (6 mm) up and down adjustment still exists on
all 4 mounts after performing final engine alignment. This is necessary to allow for realigning
engine in the future.
NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure
that the front and rear mount locations in the vessel are in parallel planes. This may be
checked by tying a string from the left front mount location to the right rear mount location
and another from right front to left rear. The strings should touch where they cross.
Page 10 of 96
Engine Compartment
WARNING
Boating standards (NMMA, ABYC) and Coast Guard regulations must be adhered
to when constructing the engine compartment.
Care must be exercised in the design and construction of the engine compartment. Seams
must be located so that any rain water that may leak through the seams, is directed away
from the air intake system.
CAUTION
Water that runs onto the air intake may enter the engine and cause serious damage
to internal engine parts.
Engine compartments are being designed to be quieter. Insulation is the most common
material used to deaden the engine sound. Normally, the quieter the engine compartment,
the more insulation material used, resulting in less air space inside. The less air space inside
the engine compartment, the hotter the inside air temperature. Attention must be given to
the air temperature while the engine is running or for a period of time after the engine is shut
off (heat soak). Refer to the following information on Engine Compartment Ventilation.
VENTILATION
According to Boating standards (NMMA, ABYC and others) and Coast Guard regulations
the engine compartment ventilation system has multiple tasks. Included are the following:
• To supply the engine with combustion air.
• To maintain a low temperature in the engine compartment.
Fresh air should enter the engine compartment as low as possible and the heated air should
be discharged from the highest point.
When sufficient ventilation is not provided, too much heat can build-up inside of engine
compartment and cause vapor locking. The engine will not want to restart after it has been
shut off for a short period of time. If it does restart, the engine will quit when given the throttle
to get the boat up on plane or to pull up a water skier.
For engines utilizing fuels containing alcohol and the newer reformulated gasolines (Refer
to OEM Service Bulletin 95-2) proper ventilation is more critical to prevent vapor locking.
If a separate air shaft (or similar) is used to provide engine compartment ventilation or
additional ventilation, care must be taken to prevent seawater and spray from entering it.
Page 11 of 96
COMBUSTION AIR REQUIREMENTS
Engine compartments with natural draft ventilation must have vent openings of sufficient
size and location to accomplish the tasks previously outlined.
IMPORTANT: The size of ventilation openings must be increased if any auxiliary
equipment is located in the engine compartment.
The combustion air requirement (per engine) for the specified engines at WOT are given
in the chart below:
Combustion Air Requirements (Per Engine)

Engine Air Requirements at
Model Engine Physical Volume
WOT
496 Mag 657 ft3/min.(.3 m3/sec.) 6.0 ft3 (170 l)
496 Mag HO 726 ft3/min. (0.342 m3/sec) 6.0 ft3 (170 l)
The pressure differential between outside and inside the engine compartment must not
exceed the following value.
Maximum Pressure Differential at WOT

2 in. (51 mm) of water (measured with a manometer)
TEMPERATURE
Air temperatures inside the engine compartments have been measured in excess of
200° F (82° C). The long term effect to fuel system components running at these
excessive temperatures is not known.
According to specification SAE J1223 for Marine Carburetors:
“The carburetor shall be capable of operation throughout an ambient (air temperature)
range from +20° to +176° F (–7° to +80° C) without failure.”
Carburetors, throttle body injection (TBI) units and components for multi-port EFI systems
used by Mercury MerCruiser meet this specification.
Under the hottest outside air temperature condition at which the boat will be operated, the
air temperature inside the engine compartment, measured at the flame arrestor, should not
exceed 176° F (80° C). Also, the temperature of the fuel being supplied to the engine should
not exceed 110° F (43° C) at any location between the fuel tank and the engine’s fuel pump.
Since many factors influence engine compartment temperature, temperature measure-
ments should always be carried out. Test as follows:
Page 12 of 96
TESTING
NOTE: The boat being tested shall be a standard production boat fitted as it would be for
delivery to a dealer.
NOTE: Temperature test meter used shall be of the type that can be read without opening
the engine cover.
IMPORTANT: During the test, in Step 1., engine compartments are to remain closed.
No outside air is to be forced into the engine compartment during the test and the
bilge blower should not be running.
1. Engine Running and Heat Soak Test:
a. Use 1 meter and 2-3 thermocouples. Place one thermocouple at the flame arrestor
to measure the inlet air temperature.
b. Place the second thermocouple at the fuel pump to measure the inlet fuel tempera-
ture.
c. A third thermocouple is needed if the fuel supply line between the tank and the fuel
pump is higher than the fuel pump. Place the third thermocouple at the highest point
of the supply line to measure the temperature of the fuel at that point.
2. Start engine and operate until engine is at normal operating temperature.
3. Operate engine at 1500 rpm (in NEUTRAL gear) for 15 minutes. Record temperature
readings at 5 minute intervals.
4. After 15 minutes at 1500 rpm, shut off engine and continue to record temperature
readings at 5 minute intervals for the next 45 minutes.
5. After the 45 minute heat soak test, start engine and idle (in NEUTRAL gear) for 20
minutes. Continue to record temperature readings at 5 minute intervals.
IMPORTANT: If the temperature at any location exceeds specifications, the engine
compartment will need additional ventilation until temperatures remain below these
specifications.
Page 13 of 96
Exhaust System
CAUTION
It is the responsibility of the boat manufacturer or installing dealer to properly lo-
cate the engine and install the exhaust system. Improper installation may allow wa-
ter to enter the exhaust manifolds and combustion chambers and severely damage
the engine. Damage caused by water in the engine will not be covered by Mercury
MerCruiser Warranty, unless this damage is the result of defective parts.
Determine if exhaust elbow risers are required, by taking measurements “a” and “b,” with
boat at rest in the water and maximum load aboard. Subtract “b” from “a” to find “c.” If “c”
is less than specified in chart, select appropriate size exhaust elbow riser kit, and exhaust
extension kit if applicable, that will correctly position exhaust elbow.
Model “c” = “a” Minus “b”

496 MAG / 496 MAG HO “c” Must Be 15 in. (381 mm) or More
b
d
a
c
77642
When designing and installing exhaust system, it is very important that the following points
be taken into consideration:
• System layout and construction must prevent cooling system discharge water from flow-
ing back into engine and also must prevent seawater from entering engine via exhaust
system.
• The exhaust hoses and pipes must not be higher than exhaust elbows at any point.
• The drop must be constant so that a low spot does not exist at any point in the exhaust
hose or pipe.
Continuous Downward Slope From Horizontal

Engine
Model Installation Minimum Maximum
Angle*
1-7/8 in. (48 mm) 4-1/8 in. (105 mm)
Sterndrive 0° 9° 19°
per 12 in. (305 mm) per 12 in. (305 mm)
* Fore - End of engine closest to bow of boat.
Page 14 of 96
• The first 18 in. (457 mm) of exhaust hose should drop the specified minimum relative to
horizontal. Thereafter, 3° of drop or 1/2 in. (13 mm) of drop per 12 in. (305 mm) relative to
horizontal is a MINIMUM requirement for the rest of the exhaust system.
• Exhaust hoses should not restrict the flow of discharge water from the elbow. The ex-
haust hose cannot be bent more than 5° relative to the exhaust elbow outlet as a hot spot
in the hose will occur and burn through.
• Exhaust outlet must be above the water line with boat at rest in the water and loaded
to capacity. The use of an internal shutter and external exhaust flapper on each outlet
is also required.
• System must not cause excessive back pressure when measured 10 in. (254 mm) aft
of the exhaust elbow outlets. Back pressure MUST NOT exceed 2 psi (14 kPa). Mini-
mum exhaust hose sizes are given in the following chart:
Minimum Exhaust Outlet Hose Size

Model Single Outlet Dual Outlet
ALL 5 in. (127 mm) 4 in. (102 mm)
• Exhaust hoses must be secured at each connection with 2 hose clamps.
THROUGH THE TRANSOM EXHAUST MODELS
When designing and installing an exhaust system, the following must be observed:
• Exhaust flanges must be of proper size to accommodate 4 in. (102 mm) I.D. exhaust
hoses and must be equipped with internal water shutters. An exhaust flapper must be
used over each outlet.
• Exhaust hoses and pipes must not be higher than exhaust elbows at any point.
• The exhaust outlet (for routing exhaust to outside of boat) must be located so that a mini-
mum of 1/2 in. (13 mm) per 12 in. (305 mm) downward pitch (drop) exists in the exhaust
hose or pipe from the engine exhaust elbow to the outlet, with a minimum drop of 4 in.
(100 mm) overall. (This is an American Boat & Yacht Council recommendation.) The
drop must be constant so that a low spot does not exist at any point in the exhaust hose
or pipe.
• Exhaust outlet must be slightly above the water line with boat at rest in the water and
a full load aboard.
• Back pressure must not exceed 4 in. (100 mm) of mercury when measured with a mercu-
ry manometer at exhaust elbow outlets.
Page 15 of 96
MAGNUM BRAVO MODEL EXHAUST RECOMMENDATION
IMPORTANT: To get maximum performance from Magnum Bravo Models, through the
transom exhaust is required. It is recommended that the exhaust bellows on the tran-
som assembly be removed. This is necessary to avoid creating a vacuum at the ex-
haust outlet in the propeller at higher boat speeds. This vacuum could degrade pro-
peller performance on some boats.
NOTE: If noise regulations do not allow the use of through the transom exhaust, an exhaust
pipe kit (Quicksilver P/N 44266A6) must be installed for through the prop exhaust. This kit
also contains an exhaust tube that is used in place of the exhaust bellows.
EXHAUST RESONATOR
CAUTION
Avoid severe engine damage. Water ingestion by the 496 cid (8.1 L) engines
may occur in some instances without the use of specially designed exhaust
resonators. Install exhaust resonators in the exhaust system when specified.
IMPORTANT: Exhaust resonators must be installed on 496 cid (8.1 L) MPI models of
sterndrive engines with through the transom exhaust.
• An exhaust resonator is included with all 496 cid / 8.1 L engines. Installation of this kit is
required on 496 MAG and 496 MAG HO sterndrive engines with a through the transom
or through the hull exhaust. MerCruiser strongly recommends the use of this kit on all
other models.
On 496 cid (8.1 L) sterndrive engines using through the transom or through the hull exhaust
systems, special care must be exercised in system design and construction to prevent an
adverse tuning effect on engine exhaust output.
• The exhaust resonator is positioned with the inside flat surface at the preferred distance
of 17 in. (432 mm) from the front edge of the exhaust hose but no closer than 2 in. (51
mm) to the exhaust outlet on sterndrives. The 17 in. (432 mm) dimension can be re-
duced, if necessary, to a MINIMUM of 13 in. (330 mm). This dimension must be the same
on both exhaust outlets.
Page 16 of 96
c c
a b a b a
a
e e
d e d
g
g
f f
b c
c
a b a e
e f
d
75768
a - Exhaust Resonator
b - Exhaust Hose
c - Dimension To Inside Flat Surface Of Resonator Approximately 17 in. (432 mm)
d - No Less Than 2 in. (51 mm) Between Collector And Resonator
e - Clamp - Positioned Around Center Of Resonator
f - Exhaust Muffler
g - Collector
Page 17 of 96
NOTE: A kit is available, when applicable, to reduce from the 4 in. (102 mm) to 3 in. (76 mm).
Refer to the Quicksilver Accessories Guide, for kit part number.
d c b
a
71774
f
Typical Continuously Sloping Exhaust Line
a - Exhaust Elbow
b - Exhaust Hose Or Pipe
c - Muffler (If Equipped)
d - Exhaust Outlet Internal Shutter
e - Exhaust Flapper Valve
f - Waterline
b
g
a
d
f
c
e
71775
Typical Waterlift Muffler Exhaust System

a - Vent Line [1/4 in. (6 mm)]
b - Transom
c - Water Line
d - Exhaust Hose
e - Drain Valve
f - Water Lift Muffler
g - Exhaust Elbow
Page 18 of 96
CAUTION
Avoid severe engine damage. A 1/4 in. (6 mm) vent hose must be run from the high-
est point in the seawater system to the exhaust pipe after the water lift muffler to
break the vacuum and prevent water from back-filling the engine.
Exhaust system tuning can be affected by various factors that are beyond the control of
Mercury MerCruiser. Following are several factors that can affect exhaust system tuning:
• Type and configuration of exhaust outlet.
• Length of exhaust hose.
• Amount of back-pressure in exhaust system.
Exhaust Resonator Kit use on Sterndrive Models:
CAN Be Used With: CANNOT Be Used With:

1. Transom mounted muffler tips. 1. Silent Choice Exhaust System.
2. Waterlift mufflers or other mufflers that 2. Below swim platform exhaust.
are mounted outboard of exhaust 3. Mufflers that mount between exhaust
elbows. elbow and exhaust tip.
3. Open exhaust.
Fuel Delivery System

WARNING
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad-
hered to when constructing the engine compartment.
The main concern of a boat’s fuel system is safety; this must be achieved through a techni-
cally sound installation and constant inspection.
The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.
The fuel tank is an integrated component of the boat. Refer to the special information on
service and maintenance, which you have received from the tank manufacturer.
Only a few points related to function and safety are listed here [Refer to boating standards
(NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:
• All connections should be on the upper side of the tank.
• The drain plug at the lowest point on the tank serves to permit the removal of water and
sediment.
• The tank breather pipe must have an inner diameter of at least 1/2 in. (13 mm) and must
be fitted with a swan neck to prevent water from entering the tank.
It is recommended that the exact route and length of the fuel lines be established at the first
installation of the engine to prevent problems later in connecting them to the engine.
All fuel lines must be well secured. The holes where the lines run through the bulkheads
should be carefully rounded off or protected with rubber grommets. This prevents damage
to the lines from abrasion.
Page 19 of 96
The following, but not limited to the following, additional fuel connection related points, ap-
plying to all engines unless otherwise stated, must be considered [Refer to boating stan-
dards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:
1. Fuel tank should be mounted below carburetor level (if possible) or gravity feed may
cause carburetor fuel inlet needle to unseat and flooding may result.
2. Fuel pickup should be at least 1 in. (25 mm) from the bottom of fuel tank to prevent pick-
ing up impurities.
3. The maximum measured vacuum at the engine’s fuel inlet must not exceed 2 in. Hg (6.9
kPa) at 600, 3000, full throttle rpm, and idle rpm.
IMPORTANT: Vacuum reading higher than specified can cause vapor locking with
some of today’s fuels. It can also cause poor engine performance because of fuel
starvation.
4. Fuel lines used must be Coast Guard approved (USCG Type A1).
Inside Diameter of Fittings and Lines 3/8 in. (10 mm)
5. On Multi-Engine Gasoline Installations: It is best to use a fuel pickup and supply line
for each engine. If a single pickup and line is used, line must not be smaller than 1/2 in.
(13 mm) I.D.
6. Larger diameter (than previously specified) lines and fittings must be used on installa-
tions requiring long lines or numerous fittings.
7. Fuel lines should be installed free of stress and firmly secured to prevent vibration and/or
chafing.
8. Sharp bends in fuel lines should be avoided.
9. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine
to absorb deflection when engine is running.
Page 20 of 96
SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS
CAUTION
The electric fuel pump and factory installed water separating fuel filter have been
carefully designed to function properly together. Do not install additional fuel filters
and/or water separating fuel filters between fuel tank and engine.
The installation of additional filters may cause:
• Fuel Vapor Locking
• Difficult Warm-Starting
• Piston Detonation Due to Lean Fuel Mixture
• Poor Driveability
WARNING
Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explo-
sive under certain conditions. NEVER use gasoline as a cleaning solvent.
IMPORTANT: The following information is provided to ensure proper installation of
brass fittings or plugs installed into fuel pump or fuel filter base:
• Use #592 Loctite Pipe Sealant with Teflon on threads of brass fittings or plugs. DO
NOT USE TEFLON TAPE.
• Brass fittings or plugs should first be threaded into fuel pump or fuel filter base
until finger tight.
• Fittings or plugs should then be tighten an additional 1-3/4 to 2-1/4 turns using
a wrench. DO NOT overtighten.
• To prevent over-tightening when installing a fuel line, the brass fittings should be
held with a suitable wrench as fuel line connectors are tightened securely.
Battery
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and
Coast Guard regulations must be adhered to when installing battery. Be sure battery
cable installation meets the pull test requirements and that positive battery terminal
is properly insulated in accordance with regulations.
IMPORTANT: It is recommended (required in some states) that battery be installed in
an enclosed case. Refer to regulations for your area.
IMPORTANT: Engine electrical system is negative (–) ground.
Select a battery that meets all of the following specifications:
• 12-volt marine type.
• Tapered post connectors or side terminal connectors. Do not use a battery with wing nut
connectors.
• Battery capacity rating of at least:
Engine
cid (l) Minimum Required Cranking Battery Size
(Cyl./Type)
V8 MPI 496 (8.1) 650 CCA / 825 MCA / 150 Ah
Page 21 of 96
MULTIPLE EFI ENGINE BATTERY PRECAUTIONS
NOTE: All references to EFI models apply to EFI and MPI Engines. The following precau-
tions apply to all EFI models.
NOTE: All references to ECM apply to all engine control modules
Situation
Alternators: Alternators are designed to charge the battery that supplies electrical power
to the engine that the alternator is mounted on. When batteries for two different engines are
connected, one alternator will supply all of the charging current for both batteries. Normally,
the other engine’s alternator will not be required to supply any charging current.
EFI Electronic Control Module (ECM): The ECM requires a stable voltage source. During
multiple engine operation, an onboard electrical device may cause a sudden drain of voltage
at the engine’s battery. The voltage may go below the ECM’s minimum required voltage.
Also, the alternator on the other engine may now start charging. This could cause a voltage
spike in the engine’s electrical system.
In either case, the ECM could shut off. When the voltage returns to the range that the ECM
requires, the ECM will reset itself. The engine will now run normally. This ECM shut down
usually happens so fast that the engine just appears to have an ignition miss.
Recommendations
Batteries: Boats with multi-engine EFI power packages require each engine be connected
to its own battery. This ensures that the engine’s Electronic Control Module (ECM) has a
stable voltage source.
Battery Switches: Battery switches should always be positioned so each engine is running
off its own battery. DO NOT operate engines with switches in BOTH or ALL position. In an
emergency, another engine’s battery can be used to start an engine with a dead battery.
Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering
accessories in the boat. They should not be used to charge the battery of another engine
in the boat unless the type of isolator is specifically designed for this purpose.
NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.
1. The boat may have 2 engines connected to a single Model 32023A battery isolator.
2. The Model 32023A battery isolator is connected to 2 banks of batteries.
3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.
4. The second battery in each bank is connected in parallel to the cranking battery.
5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2
charging sources, 120 amps (maximum alternator output).
6. When the engines are running, either engine’s alternator could be charging either bank
of batteries through the Model 32023A battery isolator.
Any other manufacturer’s battery isolator that is the same type as the Sure Power Inc.,
Model 32023A could also be used.
Generators: The generator’s battery should be considered another engine’s battery.
Page 22 of 96
BATTERY CABLES
Select proper size positive (+) and negative (–) battery cables, using chart. Battery should
be located as close to engine as possible.
IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical
contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as
it may cause corrosion and a subsequent failure.
Cable Length Cable Gauge

Up to 3-1/2 ft. (1.1m) 4 (25mm2)
3-1/2 - 6 ft. (1.1-1.8m) 2 (35mm2)
6 - 7-1/2 ft. (1.8-2.3m) 1 (50mm2)
7-1/2 - 9-1/2 ft. (2.3-2.9m) 0 (50mm2)
9-1/2 - 12 ft. (2.9-3.7m) 00 (70mm2)
12 - 15 ft. (3.7-4.6m) 000 (95mm2)
15 - 19 ft. (4.6-5.8m) 0000 (120mm2)
EFI Electrical System Precautions

NOTE: All references to EFI models apply to all EFI and MPI engines.
CAUTION
Avoid damage to the EFI electrical system components: Refer to the following pre-
cautions when working on or around the EFI electrical harness, or when adding oth-
er electrical accessories:
• DO NOT tap accessories into engine harness.
• DO NOT puncture wires for testing (Probing).
• DO NOT reverse battery leads.
• DO NOT splice wires into harness.
• DO NOT attempt diagnostics without proper, approved Service Tools.
Page 23 of 96
Instrumentation
CAUTION
If Quicksilver wiring harness is used, and a fused accessory panel is to be installed
(40-amp current draw maximum), be sure to connect it as shown in wiring diagram.
Do not connect accessory panel at any other location, as wires in wiring harness
may not be of sufficient size to handle current load.
We recommend the use of Quicksilver Instrumentation and Wiring Harness(es). On dual
station applications, oil pressure and water temperature senders (on engine) must be
changed. Refer to Quicksilver Accessories Guide for selection.
The 4 basic gauges that must be used with the engine are:
• Tachometer
• Oil Pressure
• Water Temperature
• Voltmeter
Route instrumentation wiring harness back to engine, making sure that harness does not
rub or get pinched. If an extension harness is required, be sure to secure connection
properly. Fasten harnesses to boat at least every 18 in. (460 mm), using appropriate
fasteners.
Power Trim Control

Any of the Quicksilver panel or in-handle type trim controls (that are specified for use with
Mercury MerCruiser sterndrives) can be used with this Power Trim system. Install trim con-
trol in accordance with instructions that accompany it.
Power Trim Pump Location
Select an appropriate mounting location for the trim pump that meets the following require-
ments:
• Within limits of black and gray hydraulic hoses (coming from gimbal housing assembly).
• Close to the battery so that trim pump battery leads can be connected.
• Allow easy access to trim pump oil fill and vent locations.
• Area where pump will not be exposed to water.
• Trim pump must be mounted so that when steering wheel is turned in either direction
(right or left), the power steering booster cylinder does not come in contact with trim
pump.
Page 24 of 96
Propeller Selection
IMPORTANT: Installed propeller must allow engine to run at its specified maximum
wide open throttle revolutions per minute (rpm). Use an accurate service tachometer
to verify engine operating rpm.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power
package with the correct propellers. Refer to Quicksilver publication - Everything You Need
To Know About Propellers P/N 90-8614492. Specified engine wide open throttle (WOT) and
operating rpm range are listed in the Operation, Maintenance and Warranty Manual
attached to the engine.
Select a propeller that will allow the engine power package to operate at or near the top end
of the recommended wide open throttle operating rpm range with a normal load. High rpm,
caused by an excessive trim angle, should not be used in determining correct propeller
selection.
If full throttle operation is below the recommended range, the propeller must be changed
to prevent loss of performance and possible engine damage. On the other hand, operating
an engine above the recommended operating rpm range will cause higher than normal wear
and/or damage.
After initial propeller selection, the following common problems may require that the propel-
ler be changed to a lower pitch.
• Warmer weather and greater humidity cause a loss of rpm.
• Operating in a higher elevation causes a loss of rpm.
• Operating with increased load (additional passengers, pulling skiers) causes a loss of
rpm.
For better acceleration, such as is needed for water skiing, use the next lower pitch propel-
ler. However, do not operate at full throttle when using the lower pitch propeller but not pull-
ing skiers.
Because of the many variables of boat design, only testing will determine the best propeller
for a particular application. Available propellers are listed in the Quicksilver Accessories
Guide.
See BOAT IN THE WATER TESTS, Maximum RPM Test in the power package Installation
Manual.
Page 25 of 96
RPM REV-LIMITER
IMPORTANT: When selecting a propeller consider this additional information, if

applicable:
The engines listed in the following chart are equipped with a rpm rev-limiter that is
set to an upper (or limited) rpm amount. This limit is slightly above the normal
operating range of the engine and is designed to help prevent damage from
excessive engine rpm. Once the rpm drop into the recommended operating rpm
range normal engine operation resumes.
Engine Rev-Limiter
Engine Recommended Operating
Model Rev-Limit RPM Setting
RPM Range
496 MAG 4400-4800 4950
496 MAG HO 4600-5000 5150
Seawater Connections
SEAWATER PICKUP HOSE
IMPORTANT: DO NOT install water pickup directly in line with propeller, as pickup
may create turbulence and allow air to flow into the propeller slipstream. This will
cause propeller ventilation and will adversely affect boat performance.
Water pickup must be large enough to permit sufficient water flow to engine seawater pickup
pump for adequate engine cooling. Water pickup should be located as close to seawater
pickup pump inlet as possible and in an area where an uninterrupted, solid stream of water
will flow past when boat is underway.
Water inlet hose connections must be made with wire reinforced hose of adequate wall
thickness to prevent it from collapsing from pump suction. Be sure to secure hose
connections with hose clamps. Secure hose to prevent contact with any moving parts.
Seawater Pickup Hose Inner Diameter 1-1/4 in. (32 mm)
SEACOCK
Seacock used must have an internal cross-sectional area equal to or greater than seawater
hose to prevent restricting water flow. A brass ball or gate valve is required.
Seacock Size Internal Cross-Sectional Area 1-1/4 in. (32 mm)
Install the seacock in an area where it will be easily accessible and supported adequately
to prevent hose fatigue.
SEAWATER STRAINER
Strainer used must be of sufficient size to ensure that an adequate supply of water will be
maintained for cooling engine.
Seawater Strainer Minimum Flow Rate 30 U.S. gal/min. (114 L/min.)
The seawater strainer should be installed in an area where it will be easily accessible for
inspection and cleaning. The strainer should be installed in water inlet hose after the
seacock (water inlet valve) to allow operator to shut off water when cleaning strainer.
Page 26 of 96
Hot Water Heater

IMPORTANT: When connecting a cabin heater or hot water heater, certain require-
ments must be met, including, but not limited to the following:
• Supply hose (from engine to heater) and return hose (from heater to engine)
MUST NOT EXCEED 5/8 in. (16 mm) I.D. (inside diameter).
• Make heater connections ONLY at locations indicated in the following informa-
tion.
• Refer to manufacturers’ instructions for complete installation information and
procedures.
CAUTION
Avoid a performance loss and/or possible engine damage. Engine coolant must
flow continuously from the engine intake manifold to the engine water circulating
pump. NEVER close-off or block the coolant flow to or from a heater.
All heater installations must be plumbed in series with the supply and return con-
nections.
CAUTION
Avoid engine overheating which could result in engine damage. On models
equipped with Closed Cooling, an air pocket may form in the closed cooling system
if some coolant is lost from the system and the cabin heater or hot water is mounted
higher than the fill cap on the heat exchanger. Heater must be mounted lower than
the fill cap of the heat exchanger on models so equipped.
IMPORTANT: Do not reposition engine temperature switch; it must remain where
installed by factory.
HOSE CONNECTION
a 77013
a - Supply Hose Connection

b - Return Hose Connection
Page 27 of 96
Throttle/Shift Remote Control and Cables

To ensure proper shift and throttle operation, we recommend the use of a Quicksilver remote
control and cables. Refer to Quicksilver Accessories Guide for selection. However, if a con-
trol other than Quicksilver is to be used, control must provide a shift cable travel (at the shift
plate end) of 2-7/8 in. (73mm) to 3-1/8 in. (80mm) with a 15-20 lb. (6.8-9 kg) load applied
to the cable end guide.
Steering Helm and Cable

Transom assembly is shipped with the steering cable guide tube preset for cables with end
dimensions that comply with ABYC standards as outlined in the NMMA certification hand-
book. The steering cable coupler nut must also have a means of locking it to the guide tube
as specified in ABYC requirements.
WARNING
Failure to use a steering cable locking device could cause loss of steering, which
could cause damage to the boat and/or injury.
All current production Quicksilver Ride Guide steering cables have a self-locking coupler
nut and do not require an external locking device. (Other cable manufacturers also make
cables with self-locking coupler nut.)
22060
a - Quicksilver Ride Guide Steering Cable Self-Locking Coupler Nut (Identified by

Groove)
If using a steering cable that does not have a self-locking coupler nut, an external locking
device must be used.
c
e
b
a
f
d
a - Steering Cable
b - Grease Fitting
c - Cotter Pin
d - Locking Sleeve (If Required - Must Be Ordered Separately)
e - Cable Coupler Nut
f - Cable Guide Tube
Page 28 of 96
CAUTION
POWER STEERING EQUIPPED UNITS ONLY: If steering cable with improper dimen-
sions is installed, severe damage to transom assembly and/or steering system may
result.
1. Steering cable must be the correct length, particularly when installed in larger boats.
2. Avoid sharp bends, kinks or loops in cable.
3. Fully extended steering cable end dimension must be as shown.
STEERING CABLE SPECIFICATIONS
a c
b d
e
g
f CL
k j h
l i
21435
a - Coupler Nut - 7/8 - 14 Unf - 28 Thread

b - 11-3/4 In (298 mm) Min.
c - Interface Point
d - 1/2 In (12.700 mm) Max.
e - .420 In. (10.668 mm) Min. Flat
f - .102 In. (0.508 mm) Min. Radius
g - 5/8 In. (15.875 mm) Max. Diameter End Fitting
h - 3/8 In. (9.525 mm)
i - .385 In. (9.779 mm) Diameter Through Hole, Chamfered Each Side
j - 1-3/8 In. (34.925 mm) Max
k - 5/8 In. (15.875 mm) Diameter Tube
l - Mid-travel Position - 16-7/8 In. (428.6 mm) Total Travel To Be 8 In. (203.2 mm)
Min. To 9 In (228.6 mm) Max Travel Each Side Of Mid-travel Position - 4 In.
(101.6 mm) Min., 4-1/2 In. (114.3 mm) Max.
a b
21436
a - Steering Cable Mounting Flange

b - Center Of Hole In Steering Cable End
c - 21-3/8 In (543 mm) Max.
Page 29 of 96
Transom Cutout
NOTICE to INSTALLER
Before Starting Installation Read General Information and Installation Require-
ments Sections Completely.
IMPORTANT: The following instructions will provide a sterndrive unit mounting loca-
tion that is suitable for most boats. Best mounting location for a particular boat, how-
ever, can be determined only by testing.
Bravo Models use items 1 - 4.
1. Below 25 m.p.h. (40 km/h): Subtract 1/2 in. (13mm) from “X” Dimension shown.
2. Heavy Duty Applications: Subtract 1 in. (25mm) from “X” Dimension shown.
3. Above 25 m.p.h. (40 km/h): Use “X” Dimension shown.
4. Above 50 m.p.h. (80 km/h): The “X” Dimension can be increased to improve perform-
ance in some applications, but pulling power (for skiing) will decrease. During testing,
the “X” Dimension should be increased 1/2 in. (13mm) at a time until desired perform-
ance is achieved but in no case should it ever be increased by more than:
Bravo One/Two: 3 in. (76 mm) maximum.
Bravo Three: 1 in. (25 mm) maximum.
In ALL sterndrive applications, extreme care should be taken when raising drive unit to
ensure that water supply does not become aerated. Use clear water inlet hose to monitor
incoming water and monitor engine temperature gauge to ensure engine does not overheat.
IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an in-
stalled height will not be covered by Mercury MerCruiser warranty.
Page 30 of 96
Finding Crankshaft Vertical Centerline

SINGLE ENGINE
Locate and mark vertical centerline on transom.
71620
a - Vertical Centerline
DUAL ENGINE
1. Locate and mark boat vertical centerline “a” on transom.
71620
a - Vertical Centerline
2. Locate and mark crankshaft vertical centerlines “a” on transom.
b
a a
c c
22033
a - Draw Crankshaft Vertical Centerline Through Desired Mounting Locations

b - Minimum Distance Between Crankshaft Vertical Centerlines
c - Crankshaft Vertical Centerlines Must Be An Equal Distance From Boat Vertical
Centerline
Minimum Distance Between Crankshaft Vertical Centerlines

(Dual Side-By-Side)
Model Measurement
496 cid (8.1l) 38-1/2 in. (978 mm)
Page 31 of 96
Finding Crankshaft Horizontal Centerline (X Dimension)

X Dimension can be measured by the 90° Tool Method or by the Tape Measure Method.
90° TOOL METHOD
1. Construct 90° tool.
a 90°
b
71621
a - Dimension From Chart Below

b - Measurement: 4 Ft. (1.2 M)
To Lower Drive Unit - Subtract from dimension “a.”

To Raise Drive Unit - Add to dimension “a.”
90° TOOL VERTICAL DIMENSION CHART

Sterndrive Unit Location
Bravo One/Two/Three 13-9/16 in. (345 mm)
IMPORTANT: This dimension should only be raised or lowered after proper testing.
2. Determine X Dimension location of crankshaft centerlines.
b c
c
b
a 71623
71622 a
Single Engine Dual Engine
a - Place 90° Tool Along Boat Bottom At Vertical Centerline
b - Point At Which Top Of Tool Contacts Transom On Vertical Centerline Is Crank-
shaft Horizontal Centerline.
c - Draw A Line Perpendicular To Vertical Centerline At Crankshaft Horizontal
Centerline.
Page 32 of 96
TAPE MEASURE METHOD
Transom angle must be known, then measure X Dimension with tape measure.
1. Determine X Dimension from the following chart.
Tape Measure Method Charts
Model Bravo One / Two / Three

Transom Angle This dimension should only be raised or lowered after proper
testing.
16° 14-5/16 in. (364 mm)
15° 14-1/4 in. (362 mm)
14° 14-3/16 in. (360 mm)
13° 14-1/8 in. (359 mm)
12° 14-1/16 in. (357 mm)
11° 14 in. (356 mm)
10° 13-15/16 (354 mm)
2. Measure and layout horizontal centerlines.
b b
c
c
d d
a a
71623
71622
Single Engine Dual Engine

a - “x” Dimension (From Chart) That Corresponds To Transom Angle - Measure Up
From Boat Bottom With Tape Measure
b - Crankshaft Horizontal Centerline
c - Vertical Centerline
d - Draw A Line Perpendicular To Vertical Centerline At Crankshaft Horizontal
Centerline
Page 33 of 96
Checking Transom Thickness

Ensure transom surface thickness and flatness conform to minimums specified in Installa-
tion Requirements.
70004 75479
a - Measuring Thickness
b - Measuring Flatness
c - Suitable Mandrel To Check For Uniform Transom Thickness
NOTE: Transom must be between 2 in. (51 mm) and 2-1/4 in. (57 mm) a distance of 8 in.
(203 mm) to either side of the vertical centerline.
Installing Transom Assembly

1. Carefully remove transom assembly from shipping carton.
2. Remove and read all tags which are attached to transom assembly.
IMPORTANT: When installing through the transom exhaust, it is recommended that
the exhaust bellows on the transom assembly be removed. This is necessary to avoid
creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This
vacuum could degrade propeller performance on some boats.
3. If required, remove and discard clamps and bellows from gimbal housing.
NOTE: Exhaust tube parts are provided with a Bravo Three Sterndrive. They are located
in the sterndrive unit box.
Page 34 of 96
4. If required, install exhaust tube on gimbal housing as follows:

a. Remove and discard clamps and exhaust bellows.
CAUTION
Exhaust tube clamp may corrode if grounding clip is not installed.
b. Install grounding clip on tube.
NOTE: Bellows adhesive is not used when installing an exhaust tube.
c. Position tube so that “SIDE” markings on tube are facing toward the right and left
sides.
d. Install clamp.
e. Tighten clamp. Torque to 35 lb-in. (4 Nm).
d
22184
c
b
a 22184
a - Exhaust Tube
b - Clamp
c - “SIDE” Marking
d - Exhaust Tube
e - Grounding Clip
Page 35 of 96
Installing Inner Transom Plate

1. Insert wires, hoses and shift cable through appropriate openings in inner transom plate.
2. Position gimbal housing on transom and hold in place.
NOTE: When tightening transom assembly fasteners in the following step, start in the center
and, using a circular pattern, move outward. Tighten in small increments and go around the
pattern several times until the proper torque is achieved.
a
d
c b
71626
71628
a
71627
70005
a
71629
a - Locknuts and Flat Washers (8)

b - Bolt
c - Steering Lever Continuity Wire
d - Transom Plate Continuity Wire
3. Secure transom assembly with hardware as shown. Torque to 20-25 Ib. ft. (27-34 Nm).
IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to
avoid stressing wire when steering lever moves.
Page 36 of 96
Installing Power Trim Pump

NOTE: Refer to 90-863152 for mounting hole template.
1. Mount pump in desired location.
IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from
leaking out of system. Be careful not to cross-thread or overtighten hose fittings.
2. Connect hydraulic hoses to trim pump. Torque fittings to 125 lb-in. (14 Nm).
3. Connect power trim pump control harness to trim pump.
4. Connect trim limit switch wires and secure with wire retainer and sta-strap.
c
75126
75127
f
g
a
e 50632
50630
a - Black Hose Fitting (UP Circuit)

b - Gray Hose Fitting (DOWN Circuit)
c - Control Harness
d - Sta-Strap
e - Trim Limit Switch Wire (With Blue Sleeve) To BLUE/WHITE Harness Wire
f - Trim Limit Switch Wire (With Purple Sleeve) To PURPLE/WHITE Harness Wire
g - Wire Retainer And Sta-Strap
Page 37 of 96
Installing Steering System
POWER STEERING
NOTE: For Dual Installations: Power steering unit can be mounted on port or starboard
transom assembly. Measure exact distance between power package centerlines. Select a
tie bar from Quicksilver Accessories Guide. Refer to tie bar installation instructions before
proceeding.
1. Inspect bushings for debris. Lubricate bushings with Special Lubricant 101.
B a
73898
a - Bushings
b - Special Lubricant 101
2. Remove upper and lower pivot bolts and ensure threads are well lubricated with special
lubricant 101.
3. Install steering assembly as follows:
a. Position steering assembly so that pivot bolts will enter bushings in pivot block or
power steering control valve.
b. Install upper and lower pivot bolts along with tab washers. Ensure that tab washer
tangs straddle the ridge on inner transom plate.
c. Turn pivot bolts all the way in by hand to ensure proper alignment.
d. Ensure that steering assembly pivots freely.
b
c
73899
a
c 73900
a - Tab Washers
b - Ridge
c - Pivot Bolts
Page 38 of 96
4. Torque pivot bolts to 25 lb-ft (34 Nm). Bend washer tabs against corresponding flats on
bolt heads.
5. The cylinder ram may be stiff and difficult to move when you attempt to pull it out or push
it in for installation. First move the spool assembly as shown below.
74145
a
74144
a - Control Valve Ports
6. Connect clevis to steering lever. Lubricate clevis pin with Special Lubricant 101. Spread
both ends of the cotter pin.
c
a b
71904
a - Clevis
b - Steering Lever
c - Clevis Pin
d - Cotter Pin
Page 39 of 96
7. Connect steering cable as follows:

a. Remove shipping cap from both ends of steering cable guide tube.
b. Coat steering cable end with a liberal amount of Special Lubricant 101.
c. Install steering cable and secure with hardware as shown.
h
71906
e f
73901
c
a b
71901
d 71903
a - Steering Cable
b - Grease Fitting
c - Cable Coupler Nut
d - Cable Guide Tube
e - Steering Cable End
f - Clevis
g - Clevis Pin
h - Cotter Pin
d. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical
position. Torque coupler nut to 35 lb-ft (47 Nm). Be certain the flat surfaces are
still aligned vertically after torque is applied to coupler nut.
CAUTION
Steering cable outer casing must be free to move back and forth for steering system
to function properly. Do not fasten any items to steering cable.
Page 40 of 96
SENSOR STEERING ASSEMBLY
c
a
h d
a
f
b g 77442
a - Transom Stud Holes

b - Pitot Tube Connection
c - Plug
d - Guide
e - Cotter Pin
f - Clevis Pin
g - Sta-strap
h - Alignment Mark
1. Remove nuts from upper 2 transom studs.

2. Remove cotter pin and clevis pin from steering lever.
3. Install new clevis pin and secure with existing cotter pin.
4. Slide guide onto the groove in the clevis pin.
5. Bolt the steering assembly to the transom.
6. Remove the brass plug from the transom.
7. Install pitot barbed fitting.
8. Attach pitot tube to barbed fitting and secure with a sta-strap.
9. Plug sensor into transom harness.
Page 41 of 96
Connecting Speedometer Pickup

IMPORTANT: Do not remove plug from speedometer pickup tube fitting unless
connection is to be utilized, water will leak into the boat, especially while underway.
The connection for the speedometer pickup can be accessed through a hole and fitting in
the inner transom plate.
1. Remove plug from speedometer pickup tube fitting.
b
70037
a - Plug
b - Inner Transom Plate Fitting
2. Apply Perfect Seal to threads of barb fitting. Install and torque to 13 Ib-in. (1.5 Nm).
70015
a - Barb Fitting
3. Connect a 5/32 in. (4 mm) speedometer hose (not provided) from speedometer to barb
fitting. Secure hose with cable tie.
70015
a - 5/32 in. (4 mm) Inner Diameter Speedometer Hose Fitting
4. Secure the hose to the transom with the hose clip and screw that are provided in the
parts bag.
Page 42 of 96
Connecting Sterndrive Unit Gear Lube Monitor Hose To Gimbal Housing

1. Connect the gear lube monitor hose to the quick release 90° fitting.
2. Connect the quick release 90° fitting to the gimbal housing.
IMPORTANT: Hose must not come in contact with steering system components or the
engine coupler, U-joint shaft or drive shaft.
c
a
b
75874 75313
a - Hose
b - 90° Hose Fitting
c - Gimbal Housing Fitting
d - Gear Lube Monitor
NOTE: The quick release button on hose fitting must be positioned away from water inlet
fitting, or block-off plate, if equipped. Release button must not contact water fitting, or
block-off plate, if equipped.
CAUTION
Avoid sterndrive unit damage. Quick release button on gear lube monitor 90° hose
fitting may not lock on gimbal housing if touching or depressed by water inlet
fitting, or block-off plate, if equipped. Ensure quick release button does not contact
block-off plate, or water inlet fitting if equipped. Failure to do so could result in a
loose 90° fitting causing a loss of gear lube and damage to sterndrive unit.
c b
d
f
d
71998
Block-Off Plate Installation Shown (Similar For Models With Water Fitting)
a - Block-Off Plate (Or Water Inlet Fitting If Equipped)
b - Star Washer And Screw
c - 90° Hose Fitting
d - Quick Release Button
e - ACCEPTABLE Positions
f - NOT ACCEPTABLE Position
Page 43 of 96
Engine Installation
Engine Preparation
1. Remove and read all tags attached to engine.
2. Remove all hardware that secures engine to shipping container.
3. Connect battery cables to engine. Be sure to observe the following:
a. Make sure that grounding stud and starter solenoid terminal are free of paint or any
other material that could cause a poor electrical connection.
b. After battery cables are connected, apply a thin coat of Liquid Neoprene to the termi-
nals.
c. Be sure to slide rubber boot over positive (+) terminal after making connection.
4. Drape battery cables over top of engine to prevent interference during installation.
IMPORTANT: There is a fuse located at the starter solenoid. DO NOT remove this fuse.
The positive battery cable must be connected to the same stud as the fuse.
77001
a - Positive (+) Battery Cable

b - 90 Amp Fuse - DO NOT Remove
5. Remove shipping plug from coupler and lubricate splines with Engine Coupler Spline
Grease.
6. Loosen hose clamps and remove exhaust pipe and bellows from engine.
Page 44 of 96
Transom Preparation
IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and
free of nicks and scratches and O-ring must be properly seated in groove, or water
and exhaust may leak into boat.
22059
a - Gimbal Housing Mating Surface

b - O-Ring
1. Through the Transom Exhaust Models: Install block off plate as shown, using four
bolts and lockwashers. Torque bolts to 23 lb-ft (31 Nm).
22057
a - Bolts And Lockwashers (4)

b - Block-Off Plate
Page 45 of 96
NOTE: Through the Transom exhaust fittings can be installed at this time.
2. Position rear engine mount attaching hardware on inner transom plate mounts as
shown.
c b
a 50628
a - Locknuts
b - Fiber Washers
c - Double-Wound Lockwashers
Installing Engine/Alignment
CAUTION
Engine compartment size may require the removal of additional components.
NOTE: An engine mount drilling fixture (P/N 91-806794A1) can be used to align and adjust
engine mounts. Refer to instructions with fixture for proper use.
1. Remove engine cover.
2. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when
suspended.
76938
77516
a - Rear Lifting Eye

b - Front Lifting Eye
3. Lift engine into position (in boat) using an overhead hoist.

4. Align rear engine mounts with inner transom plate mounts while simultaneously aligning
exhaust tube with exhaust pipe bellows.
Page 46 of 96
5. Install both rear engine mounting bolts and hardware as shown. Torque to 38 lb-ft
(51 Nm). Do not relieve hoist tension.
c
d
a
g
f
b
22032
a - Rear Engine Mount

b - Inner Transom Plate Mount
c - Bolt
d - Washer
e - Spacer
f - Fiber Washer
g - Double-Wound Lockwasher
NOTE: The center lifting eye tool (P/N 91-863375) used for engine alignment can be
ordered from the Quicksilver Accessories Guide.
77637
a - Center Lifting Eye Tool
Page 47 of 96
6. Align engine as follows:

a. Fold perforated area in bell housing dust cover.
22027
a - Dust Cover
CAUTION
DO NOT use an alignment tool from another manufacturer. Alignment tools other
than Quicksilver Alignment Tool may cause improper alignment and damage to
gimbal bearing and/or engine coupler.
CAUTION
To avoid damage to gimbal bearing, engine coupler or alignment tool:
• DO NOT attempt to force Quicksilver Alignment Tool!
• DO NOT raise or lower engine with alignment tool inserted (or partially inserted)
in gimbal bearing or engine coupler.
• DO NOT raise engine mount bracket above top of engine mount stud.
b. Attempt to insert the solid end of the alignment tool through the gimbal bearing and
into the engine coupler splines.
Page 48 of 96
c. If the tool does not fit, remove it and carefully raise or lower the front end of the engine
as necessary, and attempt to insert the alignment tool.
d. Repeat step c. until the alignment tool installs easily. This may require tapping the
sides of the tool. Do not check by turning. By greasing the splines you can identify
which side has interference.
76921
27647
a - Alignment Tool
b - Gimbal Bearing
c - Engine Coupler
Page 49 of 96
IMPORTANT: Finished boat stringer must position engine so that a minimum mount
adjustment exists after front mount is adjusted down to stringer. This allows for
future adjustments.
IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in
direction required to align engine.
7. Adjust front engine mounts until they rest on boat stringers.
8. Relieve hoist tension entirely and fasten both front mounts to boat stringer using 3/8 in.
(9 mm) lag bolts.
9. Recheck alignment with alignment tool. Tool must enter coupling splines freely. If not,
readjust front mounts.
10. When alignment is correct, tighten locknut securely. Recheck alignment.
11. Bend tab down on adjusting nut.
a
b d
c
71649
a - Nut And Lockwasher

b - Adjustment Nut
c - Direction (Counterclockwise) To Raise Front Of Engine
d - Tab Washer
12. Remove alignment tool and fold bell housing dust cover flap back into place and tape
shut for boat shipment. Dust cover flap will have to be removed before operating engine.
Page 50 of 96
Engine Connections
IMPORTANT: When routing all wire harnesses and hoses, ensure they are routed and
secured to avoid coming in contact with hot spots on engine or moving components.
1. Connect water hose to water inlet fitting and secure with hose clamp.
a
b
72040
a - Water Inlet Fitting

b - Hose
c - Hose Clamp
2. Connect continuity circuit wire from engine to transom assembly.

IMPORTANT: Do not attach any accessory ground (–) wires to transom plate ground
point. Accessory ground wires can only be attached to ground stud on engine.
a
c 72052
d 71651
a - Rubber Boot (Not Shown)

b - Positive (+) Battery Cable
c - 90 Amp Fuse DO NOT Remove
d - Negative (–) Battery Cable
Page 51 of 96
IMPORTANT: Avoid using excessive hose when routing the gear lube monitor. Hose
should be routed directly to oil reservoir in as straight a line as possible to avoid low
spots (traps) in the system.
CAUTION
Ensure hose is not kinked in the following step. If hose is kinked, gear lube monitor
will not function properly and damage to sterndrive unit could occur.
3. Route gear lube monitor hose from drive, under ECM bracket to gear lube monitor and
cut off excess hose.
a
b 77007
a - Hose
b - ECM Bracket
4. Connect hose and secure with hose clamp. Secure hose with the J-clip that is attached
to the valve cover.
CAUTION
Route hydraulic hoses exactly as shown below. This will help avoid stress on the
hose fittings and kinks in the hose.
IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid
leaks.
IMPORTANT: Be careful not to cross-thread or overtighten fittings.
5. Route hoses over top edge of transom plate. Secure hoses to avoid contact with moving
components.
6. Connect power steering hoses to control valve. Torque both fittings to 23 lb-ft (31 Nm).
75117
a - Rear Fitting (Pressure Hose)

b - Front Fitting (Return Hose)
Page 52 of 96
7. Use extra hose clips to secure hose to transom.

8. Connect fuel line to boost pump.
a
b
77629
a - Water Separating Fuel Filter

b - Fuel Boost Pump
c - Fuel Pump (Not Shown)
9. Tighten all exhaust hose and/or exhaust tube clamps securely.
CAUTION
Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around
entire inside diameter of hose to avoid causing hot spots which could eventually
result in burned-through exhaust hoses. Exhaust hoses and/or tubes must be
correctly connected to exhaust elbows so that they do not restrict the flow of
discharge water from exhaust elbow.
b
a
b
a
77593
a - Exhaust Tubes
b - Clamps
Page 53 of 96
10. Connect instrumentation wiring harness to engine harness plug. Secure connection
with hose clamp.
76938
a - Engine Harness Plug
11. Connect power trim pump wires to battery.
76631
a - Positive Battery Lead
b - Negative Battery Lead
Page 54 of 96
12. Connect transom harness to engine harness

13. Connect trim sensor and trim limit wires.
b c f
d C4 e
C5
T2 T1
C2
C3
A B C A B C AB C A B C
PPL
BLU
BLK/BRN
WHT/BLU
BLK/BRN
GRY
PNK
ORN
GRY
GRY
BLK/BRN
RED RED
4 BLU BLU
3
GRN
GRN
GRY
BLK/BRN
2
PNK
GRY
BLU 1
PPL ORN
WHT/BLU
BLK/BRN
PPL
PNK
BLU
GRY
ORN
GRN
PLUG
PLUG
KJ H G F E DC B A
a
77689
Transom Harness (P/N 863360)

a - Transom Harness To Engine Harness Connector
b - Trim Limit Connectors On Mechanical Throttle and Shift
c - Steering Sensor Connector
d - Speedometer Sensor
e - Trim Sensor
f - Trim Pump Connector For Electronic Throttle And Shift
Page 55 of 96
d
a
f
e
b
77717
c
Transom Harness (P/N 863739A1)

a - To Trim Sensor
b - To Trim Limit
c - Not Used
d - To Speedometer / Steering Sensor
e - BLK/BRN Splice
f - GRY Splice
g - Transom Harness (P/N 863739A1)
NOTE: Harness (P/N 863739A1) works with Steering Sensor Assembly (P/N 863188A3).
Harness (P/N 863360) works with Steering Sensor Assembly (P/N 863188A2).
14. Connect wires to MerCathode controller assembly as shown. Apply a thin coat of liquid
neoprene to all connections.
IMPORTANT: Opposite end of RED/PURPLE wire must be connected directly to
battery positive (+) terminal. DO NOT connect it to a switched positive (+) circuit.
MerCathode system must function continuously for proper corrosion protection.
a b c d 22232
a - ORANGE Lead - From Electrode On Transom Assembly

b - RED/PURPLE Wire - Connect (Other End) To Positive (+) Battery Terminal
c - BLACK Wire - From Engine Harness
d - BROWN Wire - From Electrode On Transom Assembly
Page 56 of 96
Audio Warning System Connection

WARNING
Alarm is not external ignition-proof, therefore, DO NOT mount alarm in engine or
fuel tank compartments.
1. Select a location for audio warning alarm which meets all of the following:
• alarm can be easily heard, yet is out of sight
• alarm can be easily accessed for installation and maintenance
• alarm will remain dry
• alarm is within length limits of the 18 in. purple alarm wire that connects to the “I” terminal
or 12 volt source on switched side of ignition switch.
2. Place alarm in desired location and secure to wire bundle with sta-strap provided.
3. Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge
or ignition switch. Tighten connection securely.
4. Connect TAN/BLUE wire from alarm to TAN/ BLUE wire from instrument harness.
5. Place the small (transparent) decals on the bottom of the water temperature and the oil
pressure gauges.
6. Place the large decal on the instrument panel or other appropriate location in easily
viewed by the operator.
ALARM INDICATES LOW

OIL OR OVERHEATING
a
APPLY THE PROPER DECAL TO THE DASHBOARD

OR OTHER APPROPRIATE LOCATION: b
AUDIO WARNING HORN WILL SOUND WHEN:

1. ENGINE OIL PRESSURE IS TOO LOW
2. ENGINE TEMP. IS TOO HIGH, OR
3. DRIVE OIL LEVEL IS TOO LOW
TO TEST AUDIO WARNING HORN:

TURN KEY TO “ON” POSITION (ENGINE OFF)
75430
Choose Appropriate Decal for Your Package

a - Small Decal (Transparent)
b - Larger Decal
7. Test audio warning system during Predelivery Preparation section.
Page 57 of 96
Quick Drain Oil Installation (If Equipped)

1. Fasten flange to hull with appropriate fasteners (not provided).
2. Push end of oil drain hose out of boat hull through flange.
3. Pull oil drain hose out until it is 6 in. (152 mm) from the propeller.
4. Move alignment clip on the oil drain hose and squeeze to position it on the hose just in-
side of the boat hull against the flange.
5. Connect bilge drain plug to oil drain hose plug using clip.
b f
a c
76882
a - Bilge Drain Plug

b - Tether
c - Quick Oil Drain Hose Plug
d - Flange
e - Toward Interior Of Boat
f - Clip
IMPORTANT: If Quick Drain Oil Fitting is within 1/2 in. (6 mm) of boat bottom, remove
fitting and install drain plug from parts bag directly into oil pan.
6. Push oil drain hose through flange into boat hull.
7. Install bilge drain plug in hull.
Page 58 of 96
Shift Cable Installation and Adjustments

Installing Sterndrive Unit Shift Cable
NOTE: Using Adjustment Tool (P/N 91-12427), shift cables can be adjusted without or with
the sterndrive installed, using the following procedure.
IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable
installation in the remote control.
• Bravo One/Two - If shift cable end guide moves in direction A when control lever
is placed in Forward, remote control is set up for RIGHT HAND (RH) propeller
rotation.
• Bravo One/Two - If shift cable end guide moves in direction B when control lever
is placed in Forward, remote control is set up for LEFT HAND (LH) propeller
rotation.
B
71656
Arrow Indicates Direction Of Motion

• Bravo Three - Front propeller on sterndrive unit is always LH Rotation and rear
propeller is always RH Rotation. Shift cable end guide must move in direction A,
when control lever is placed in Forward gear position.
71656
IMPORTANT: When installing shift cables, be sure that cables are routed in such a
way as to avoid sharp bends and/or contact with moving parts. DO NOT fasten any
items to shift cables.
1. Install shift cable into remote control. (Refer to appropriate remote control instructions.)
2. Loosen stud and move it to dimension, as shown. Retighten stud.
a
b
71657
a - Stud
b - 3 in. (76 mm) (Center Of Pivot Bolt To Center Of Stud)
Page 59 of 96
3. Install sterndrive unit shift cable. Tighten locknut until it contacts, then loosen 1/2 turn.
4. Inset cotter pin from the top and spread both ends to secure.
a
c
b
71658
a - Washers (2)
b - Locknut
c - Cotter Pin
5. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place, using
a piece of tape over the barrel retainer.
71659
a - Adjustment Tool
Page 60 of 96
6. Locate center of remote control and control cable play (backlash).

a. Shift remote control to neutral.
b. Push in on control cable end with enough pressure to remove play and mark position
“a” on tube.
c. Pull out on control cable end with enough pressure to remove play and mark position
“b” on tube.
d. Measure distance between marks “a” and “b” and mark position “c” half-way
between marks “a” and “b.”
b
a
71656
IMPORTANT: Be sure to keep center mark “c” aligned with control cable end guide
edge when making the following adjustment.
7. Adjust control cable as follows:
a. Temporarily install control cable end guide into shift lever and insert anchor pin.
b. Adjust control cable barrel so that hole in barrel centers with vertical centerline of
stud. Ensure that backlash center mark is aligned with edge of control cable end
guide.
CAUTION
DO NOT attempt to install or remove control cable barrel from stud without first
removing end guide anchor pin from shift lever and removing cable. Attempting to
bend control cable to install or remove barrel will place undue stress on cable end
guide and shift lever and damage to both could occur.
c. Remove control cable end guide from shift lever by removing anchor pin.
b a c
d
71660
a - Control Cable End Guide

b - Anchor Pin
c - Backlash Center
d - Control Cable Barrel
e - Stud
Page 61 of 96
8. Install control cable, with washers on both sides of the barrel. Tighten locknut until it con-
tacts.
9. Insert cotter pin and spread both ends to secure.
c
b
71661
a - Locknut
b - Washers
c - Anchor Pin
d - Cotter Pin (Not Visible)
a
c b
71663
LH Rotation Bravo One And Two

a - Adjustment Tool
b - Barrel Retainer
c - Shift Lever Stud
d - Shift Lever Adjustment Slot
10. Remove adjustment tool.

11. Lubricate shift cable pivot points with 30W oil.
Page 62 of 96
Troubleshooting Shift Problems

NOTE: The following information is provided to assist an installer in troubleshooting if hard
shifting or chucking/racheting is encountered when shifting into forward gear.
a
a
a a
22005
a - Lubrication Points
1. DO NOT fasten the shift cable with straps or clamps to any other cable within 5 ft.
(1.5 m) of the shift plate.
2. DO NOT fasten the shift cable to the transom with any type of plastic clips or fasteners
within 5 ft. (1.5 m) of the shift plate.
3. DO NOT overtighten the throttle or shift cable attaching nuts at the engine end. Barrel
and cable end must be free to rotate on the mounting stud.
NOTE: Lubricate attaching points with engine oil.
4. Check the sterndrive shift cable routing from the transom assembly to the shift plate as
follows:
a. Route the cable through the transom above the exhaust pipe and turn it toward the
starboard side of the boat between the exhaust pipe and the engine flywheel hous-
ing.
b. Next, route the cable under the starboard rear engine mount and turn it toward the
transom.
c. Then route the cable up behind the power steering valve and loop it over to the shift
plate on the engine and connect it to the anchor points on the shift plate.
Following this routing will prevent the engine coupler from damaging the cable.
NOTE: A final check of the adjustments should be made with the boat in the water and
engine running. If this cannot be done or is not done at your manufacturing facility,
arrangement should be made with the dealer to do this as part of the pre-delivery inspection.
Page 63 of 96
Throttle Cable Installation and Adjustment

1. Place remote control handle(s) in neutral idle position.
IMPORTANT: Be sure that cable is routed to avoid sharp bends and/or contact with
moving parts. DO NOT fasten any items to throttle cable. Outer cable must be free to
move when cable is actuated.
2. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle
lever end. (This will place a slight preload on shift cable to avoid slack in cable when
moving remote control lever.) Adjust barrel on throttle cable to align with hole in anchor
plate. Ensure hole in barrel positions cable as shown.
b 76899
Typical
a - Flat Washer and Locknut
b - Cable Barrel
c - Flat Washer And Locknut
3. Secure throttle cable with hardware as shown and tighten securely. Loosen locknut “a”
1/2 turn.
4. Place remote control throttle level in the wide open throttle (WOT) position. Ensure that
throttle plates are completely open.
5. Return remote control throttle lever to idle position and ensure that throttle lever is com-
pletely closed.
Page 64 of 96
Sterndrive Unit Installation

1. Remove trim cylinder support and dust cover from bell housing studs. Retain elastic stop
nuts and flat washers.
2. Remove monitor cap and fill gear lube monitor with High Performance Gear Lube.
77630
a - Gear Lube Monitor
3. Push in on dribble valve until gear lube appears. Release dribble valve.
72471
a - Dribble Valve
4. Fill monitor to FILL mark and replace monitor cap.
Page 65 of 96
5. Coat studs with 2-4-C Marine Lubricant with Teflon.
77066
a - Studs (6)
6. Lubricate U-joint shaft splines and U-joint shaft O-rings with Engine Coupler Spline
Grease.
7. Inspect drive shaft bellows for cleanliness.
72472
a - Drive Shaft Bellows
Page 66 of 96
8. Lubricate O-ring seals with 2-4-C Marine Lubricant with Teflon.
a
72183
a - O-ring Seals
9. Pull out shift linkage as far as possible. Jaws will open.
72460
a - Shift Linkage
Page 67 of 96
IMPORTANT: As sterndrive is inserted into sterndrive unit, entry of the bell housing
shift cable must be closely monitored to ensure that cable enters the jaws of shift
linkage assembly in the sterndrive.
10. Place remote control in NEUTRAL position.
NOTE: As bell housing shift cable enters the shift linkage assembly, it pushes the assembly
back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps
“A”, “B” and “C.”
C
72467
IMPORTANT: If Bell Housing Shift Cable “b” does not line up to properly enter jaws
of shift linkage assembly “a,” cable will have to be aligned manually.
72457
a - Shift Linkage Assembly

b - Shift Cable
Page 68 of 96
11. Place drive shaft housing in position on bell housing and install sterndrive unit, as fol-
lows:
a. Position trim cylinders so they point straight backwards.
b. Position sterndrive unit so that universal joint shaft aligns with bell housing bore.
c. Guide U-joint shaft through bearing in gimbal housing and into engine coupler.
Ensure that shift linkage jaws engage the bell housing shift cable assembly.
d. If necessary, rotate propeller shaft counterclockwise slightly (using a propeller) to
align U-joint shaft splines with splines in engine coupling, then slide sterndrive unit
all the way into bell housing.
12. Secure sterndrive unit to bell housing with 5 flat washers and 6 locknuts. Torque
to 50 Ib-ft (68 Nm).
71244
a - Do Not Install Flat Washer Here

b - Elastic Stop Nuts (6) And Flat Washers (5)
Page 69 of 96
IMPORTANT: The Trim-In Limit Pin must be properly positioned before installing the
trim cylinder anchor pin in the following steps.
13. Ensure that the Trim-In Limit Pin is positioned as shown for the appropriate Bravo model.
75157
Bravo One and Two (Positioned Forward)
75158
Bravo Three (Positioned Aft)

a - Trim-In Limit Pin
Page 70 of 96
IMPORTANT: The position of the Trim-In Limit Pin on the Bravo Three sterndrive unit
should only be changed after the boat has been properly tested. Refer to appropriate
Mercury MerCruiser Applications Manual.
IMPORTANT: To aid in installing rubber bushings, use a water and soap solution. DO
NOT use oil or grease.
14. Install trim cylinders on aft end of sterndrive unit with hardware as shown. Coat anchor
pin threads with 2-4-C Marine Lubricant with Teflon and tighten nuts until they contact.
Install plastic caps and tighten hand tight only.
b
c c
a
d e
c
f
71668 71669
a - Aft Anchor Pin

b - Large l.D. Flat Washers (2)
c - Rubber Bushings (4)
d - Small l.D. Flat Washers (2)
e - Locknuts (2)
f - Plastic Caps (2)
15. Place sterndrive unit serial number decal as described in General Information.
16. On Bravo One and Two Sterndrive Units - Perform steps 17. through 19.
17. Raise sterndrive to gain access to area between gimbal housing and sterndrive, imme-
diately atop the transom end of the anti-ventilation plate.
Page 71 of 96
18. Insert speedometer tube fitting into opening on topside of anti-ventilation plate, in posi-
tion shown.
22025
a - Tube Fitting
b - Opening
19. With fitting fully seated, turn handle to left to a tightly seated position.
22025
a - Handle
Page 72 of 96
Predelivery Preparation
NOTICE TO INSTALLER
Before starting Predelivery read General Information and Installation Require-
ments completely.
Once the power package installation is complete, the following final steps should be taken
to prepare power package for delivery to the customer. It is the boat manufacturer’s
responsibility to perform these procedures, or to make arrangement with the dealer to have
these procedures completed.
Battery Connection
IMPORTANT: Engine electrical system is negative (–) ground.
1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal.
2. Connect engine negative (-) battery cable (usually BLACK) to negative (-) battery termi-
nal.
3. Connect power trim pump BLACK (-) battery cable to negative (-) battery terminal and
pump RED (+) battery cable to positive (+) battery terminal.
4. Make sure that all battery terminal connections are tight, then spray terminals with a bat-
tery connection sealant to help retard corrosion.
Power Trim Pump

IMPORTANT: Check oil level with sterndrive unit in the full down position.
IMPORTANT: Use Quicksilver Power Trim and Steering Fluid, or SAE 10W-30 or
10W-40 engine oil in trim system.
1. Unscrew fill cap, remove and discard cap plug from fill neck. Replace fill cap.
50630
a - Cap Plug
Page 73 of 96
2. Raise and lower sterndrive unit 6 to 10 times to purge air from system. Check oil level
visually, (with sterndrive unit in the full DOWN position). Oil level should be maintained
at bottom lip of fill neck.
22031
a - Fill Neck
3. Check all trim line connection points for leaks. If fluid is visible at fittings, tighten fittings.
Torque fittings to 125 lb-in. (14 Nm).
Trim Position Sender Adjustment

ANALOG GAUGES
1. Loosen both trim position sender retaining screws.
71220
a - Retaining Screws
b - Trim Position Sender
Page 74 of 96
CAUTION
DO NOT start engine in the following step or damage to sterndrive unit and engine
could result from lack of cooling water.
2. Turn ignition key to RUN position.
3. Trim sterndrive unit to the full DOWN/IN position.
4. Rotate trim position sender as required to show full DOWN/IN position on dashboard
instrument as shown.
a
71671
a - Trim Gauge Needle
5. Tighten retaining screws and turn ignition key to the OFF position.
71220
Page 75 of 96
DIGITAL GAUGES
IMPORTANT: Trim limit is controlled by the ECM. Trim limit is factory set at 10 counts
or 0.7 volts at full trim IN. If trim is adjusted to less than 0.5 volts at full trim IN, the
ECM will enter diagnostic mode and will not function.
NOTE: The trim limit can be adjusted from 25 counts (UP) to 0 counts (DOWN). It is factory
set at 10 counts.
1. Loosen both trim position sender retaining screws.
71220
2. Adjust position of trim sender in slots.
71220
a - Slots
3. Check voltage.
NOTE: Lowering the voltage will raise the overall limit angle.
Page 76 of 96
Power Steering Fluid

IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III
automatic transmission fluid (ATF) in power steering system.
CAUTION
DO NOT RUN POWER STEERING DRY, or pump will be damaged.
1. Center sterndrive unit.
2. Remove fill cap from power steering pump reservoir and check fluid level.
3. Add fluid as required.
NOTE: When first starting engine, be prepared to add fluid to pump.
77569
b
77623
77630
a - Fill Cap
b - Dipstick
Propeller Installation (Bravo One and Two)

IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller
shaft.
WARNING
Ensure that remote control is in neutral position and ignition key is removed from
switch prior to installing propeller.
WARNING
Place a block of wood between the anti-ventilation plate and propeller to protect
hands from propeller blades and to prevent propeller from turning when tightening
propeller nut.
1. To aid in future removal of the propeller, liberally coat propeller shaft splines with one
of the following Quicksilver lubricants.
• Special Lubricant 101
• 2-4-C Marine Lubricant with Teflon
IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are
exposed through propeller nut after torquing it.
Page 77 of 96
2. Install propeller with attaching hardware as shown. Tighten nut a minimum of 55 lb-ft
(75 Nm), then continue to tighten until 3 tabs on the tab washer align with grooves on
spline washer. Bend the 3 tabs down into grooves.
a
b
c
e
d f g 76910
Bravo One
a - Propeller Shaft
b - Forward Thrust Hub
c - Flo-Torque Drive Hub
d - Propeller
e - Drive Sleeve Adapter
f - Tab Washer
g - Locknut
b
c
d e f 70561
Bravo Two
a - Propeller Shaft
b - Forward Thrust Hub
c - Propeller
d - Continuity/Spline Washer
e - Tab Washer
f - Locknut
Page 78 of 96
Propeller Installation (Bravo Three)

IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller
shaft.
WARNING
Be sure that remote control is in NEUTRAL position and ignition key is removed
from switch prior to installing propeller.
WARNING
Place a block of wood between the anti-ventilation plate and propeller to protect
hands from propeller blades and to prevent propeller from turning when tightening
propeller nut.
1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one
of the following Quicksilver lubricants.
• Special Lubricant 101
• 2-4-C Marine Lubricant with Teflon
2. Install propellers with attaching hardware as follows:
a. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.
b. Align splines and place front propeller on propeller shaft.
c. Install front propeller locknut. Torque to 100 lb-ft (136 Nm).
d. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub.
e. Align splines and install aft propeller.
f. Install propeller locknut. Torque to 60 lb-ft (81 Nm).
e f
d
b c
77107
Bravo Three
a - Rear Propeller Locknut
b - Rear Propeller
c - Rear Propeller Thrust Hub
d - Front Propeller Locknut
e - Front Propeller
f - Front Propeller Thrust Hub
Page 79 of 96
Test Running Engine

WARNING
If engine is to be tested with boat out of water, the propeller must be removed to
avoid injury.
IMPORTANT: If using a test tank, ensure water level is above water intake holes.
70082
Typical
a - Minimum Water Level
b - Water Intake Holes
IMPORTANT: Low water pickups must be suitably blocked during flushing to ensure
proper water flow to engine.
IMPORTANT: If using flush device, install over water intake holes and connect a water
hose as shown. Do not use full water tap pressure. Also, do not operate engine above
1500 rpm, as suction created could cause water hose to collapse causing water
supply to be cut off.
b 70564
a - Flush Device
b - Water Hose Hook-Up
Page 80 of 96
WARNING
Do not leave helm unattended when making test with boat in the water.
1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight.
NOTE: Refer to appropriate Mercury MerCruiser Operation, Maintenance and Warranty
Manual for operating specifications.
2. Check crankcase oil level.
IMPORTANT: Oil level in monitor will rise and fall during sterndrive operation; always
check oil level when sterndrive is cool and engine is shut down.
3. Check sterndrive unit oil level.
4. Check drive belt tension.
5. Test audio warning system.
6. Start engine and operate at IDLE rpm until water temperature is normal.
7. Watch all gauges for normal readings.
8. Turn steering wheel starboard, then port, and ensure that sterndrive unit turns the cor-
rect way.
9. Inspect engine compartment for water, oil, fuel and exhaust leaks.
10. Check power steering system for lugging condition.
a. Turn steering wheel LEFT/PORT until it stops and continue to apply pressure. If
pump lugs (engine rpm drops and/or power steering pump tone changes), check the
following.
(1.) Check for an obstruction between gimbal ring and gimbal housing and all moving
steering components.
(2.) Ensure that steering lever is not contacting cutout in transom. If contact is being
made, modify cutout.
b. Turn steering wheel RIGHT/STARBOARD until it stops and continue to apply pres-
sure. If pump lugs (engine rpm drops and/or power steering pump tone changes),
check the following.
(1.) Check same items as (1.) and (2.) above.
(2.) Check steering cable end dimension with cable fully extended. (Refer to
Applications Manual for proper steering cable dimensions).
Page 81 of 96
11. Check power steering fluid level.

a. Turn off engine.
b. Remove cap from power steering pump. Check fluid level on dipstick and add as
necessary.
a b
77623
77569
a - Dipstick (Full When Cold Line)

b - Dipstick (Full When Hot Line)
Boat In The Water Tests

WIDE OPEN THROTTLE TEST
IMPORTANT: To operate engine at full throttle before the break-in period is complete,
follow this procedure.
1. Start engine and operate at idle rpm until normal operating temperature is reached.
2. Bring boat up on plane.
3. Advance engine rpm (in 200 rpm increments) until engine reaches its maximum rated
rpm.
To test if the correct propeller has been installed, operate boat (with normal load on board)
at WOT and check rpm with an accurate tachometer. Engine rpm should be near top of the
specified range so that under a heavy load engine speed will not fall below specifications.
If engine speed is too high, replace propeller with a higher pitch propeller.
Page 82 of 96
Cold Weather or Extended Storage Draining Instructions

NOTE: If recommended coolant is unavailable, any type of ethylene glycol based antifreeze
may be used, but it will require replacement every two years.
IMPORTANT: Drain seawater section of closed cooling system only.
IMPORTANT: Boat must be as level as possible to ensure complete draining of
cooling system.
CAUTION
Seawater section of cooling system MUST BE COMPLETELY drained for winter
storage or immediately after cold weather use if the possibility of freezing
temperatures exist. Failure to comply may result in trapped water causing freeze
and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by
the Mercury MerCruiser Limited Warranty.
CAUTION
If engine will be exposed to freezing temperatures, ensure closed cooling section
is filled with an ethylene glycol antifreeze and water solution properly mixed to pro-
tect engine to lowest temperature to which it will be exposed.
IMPORTANT: Closed cooling section must be kept filled year-round with
recommended coolant.
IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section
of the engine.
CAUTION
Ensure that boat is out of the water or seacock is closed and that bilge pump is oper-
ating. Excess water in the bilge can damage engine or cause boat to sink.
SINGLE POINT DRAIN SYSTEM
CAUTION
Freeze damage can occur if operating where temperatures are below 32° F. Use
Manual Drain System to ensure heat exchanger is completely drained.
NOTE: This procedure is written for the air pump that is attached to the engine. However,
any air source can be used.
1. Remove air pump from engine.
2. Ensure that lever on top of pump is flush with the handle (horizontal).
Page 83 of 96
3. Install air pump on the actuator fitting.
77638
77516
a - Actuator Fitting
b - Green Indicators
c - Manual Release Valve
d - Air Pump
4. Pull lever on air pump up (vertical) to lock pump on actuator fitting.

5. Pump air into the system until both green indicators extend and water drains from both
sides of the engine.
6. Most water will drain from the engine in 3-4 minutes, however, some will remain trapped
in the heat exchanger. In order to prevent freeze damage, leave system pressurized
while transporting boat or during other maintenance items to allow the remaining water
to drain.
IMPORTANT: Before launching boat, pull up on manual release valve. Verify that
green indicators are no longer extended.
CAUTION
Manual release valve may not close completely. Ensure valve is completely seated.
Page 84 of 96
MANUAL DRAIN SYSTEM
NOTE: If air actuated drain system fails, use the blue drain plugs to drain engine.
NOTE: It may be necessary to lift, bend or lower hoses to allow water to drain completely
when hoses are disconnected.
1. Remove blue drain plugs from front and rear of cool fuel cell and from the seawater
pump.
2. Remove end caps, sealing washers and gaskets from heat exchangers.
b
c
d
71515
a - Heat Exchanger
b - Gaskets
c - Sealing Washer
d - End Cap
3. Repeatedly clean out drain holes using a stiff wire. Do this until entire system is drained.
4. Remove both hoses from seawater pump.
77512
a - Seawater Inlet Hose

b - Hose To Cooler
Page 85 of 96
5. Insert a small wire (repeatedly) to ensure speedometer pitot tube, trim tab cavity vent
hole, and trim tab cavity drain passage are unobstructed and drained.
c
a
71217
Typical Bravo Drive Unit

a - Speedometer Pitot Tube
b - Anode Cavity Vent Hole
c - Anode Cavity Drain Passage
6. Crank engine over slightly with starter motor to purge any water trapped in seawater
pickup pump. DO NOT ALLOW ENGINE TO START.
Store boat with sterndrive unit in full DOWN/IN position.
Page 86 of 96
THIS PAGE IS INTENTIONALLY BLANK
Page 87 of 96
Coolant And Water Flow Diagrams

NOTE: Certain components in the following diagram may look different than on your
particular power package, but the water and coolant flow paths remain similar on all
engines.
14
12
c
13
b
a
4
3
6
d
14
2
12
8
c
7
13
10
11
Page 88 of 96
1 - Seapump
2 - Air Actuator
3 - Transmission Cooler
4 - Oil Cooler
5 - Fuel Cooler
6 - Air Actuator
7 - Heat Exchanger
8 - Thermostat
9 - Crossover
10- Water Circulating Pump
11- Coolant Reservoir
12- Exhaust Manifold
13- Elbow
14- Water And Exhaust Outlet
a - Seawater
b - Coolant
c - To Air Actuator
d - Seawater Inlet
Page 89 of 96
Power Trim System Wiring Diagram
b
a
c
f
e
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
h RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LT OR LIT = LIGHT
DRK = DARK
73962
Page 90 of 96
a - 20 Amp Fuse
b - Ground Bolt (Floor Mount)
c - “UP” Solenoid
d - 110 Amp Fuse
e - “DOWN” Solenoid
f - Trailer Switch
g - Neutral Switch to Instrument Wiring Harness
h - Trim Limit Switch
Page 91 of 96
Quicksilver Instrumentation Wiring Diagrams

MCM Gasoline Engine
SINGLE STATION INSTALLATIONS - TYPICAL
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
PNK = PINK
PUR = PURPLE
a RED
TAN
=
=
RED
TAN
WHT = WHITE
YEL = YELLOW
LIT OR LT = LIGHT
DRK = DARK
b
c d e
f
g
h
i
i
74583
Page 92 of 96
Refer to gauge manufacturer’s instructions for specific connections.

NOTE 1: Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Con-
nection and Slide Rubber Sleeve over Connection.
NOTE 2: Power for a Fused Accessory Panel May Be Taken from This Connection. Load
Must Not Exceed 40 Amps. Panel Ground Wire Must Be Connected to Instrument Terminal
That Has an 8-Gauge Black (Ground) Harness Wire Connected to it.
NOTE 3: Lanyard stop switch lead and neutral safety switch leads must be soldered and
covered with shrink tube for a water proof connection. If an alternate method of connection
is made, verify connection is secure and sealed for a water proof connection.
a - Audio Warning Buzzer
b - Tachometer
c - Oil Pressure
d - Water Temperature
e - Battery Meter
f - Ignition Switch
g - Trim Indicator
h - Read/Observe NOTE 1 and 2.
i - Read/Observe NOTE 3.
j - To Engine Wiring Harness
Page 93 of 96
MerCathode System Wiring Diagram
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN= GREEN
ORN= ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT= WHITE
YEL = YELLOW
c LT OR LIT=LIGHT
DRK = DARK
73596
a - Controller
b - 20 Amp Fuse
c - Electrode
Page 94 of 96
THIS PAGE IS INTENTIONALLY BLANK
Page 95 of 96
Predelivery Inspection
Not Check/ Not Check/
Applicable Adjust Applicable Adjust
CHECK BEFORE RUNNING ON THE WATER TEST
Drain plug in and petcocks Engine alignment (Inboards only)
closed
Seawater inlet valve open Starter neutral safety
switch operation
Engine mounts tight
Water pump operation
Engine alignment
Instruments(s) operation
Drive unit fasteners torqued
Fuel leaks
Power trim cylinders fasteners
tight Oil leaks
Battery fully charged and secured
Water leaks
All electrical connections tight
Exhaust leaks
Exhaust system hose clamps
tight Ignition timing
All fuel connections tight
Idle rpm, within specifications
Correct rotation propeller
(installed and torqued)
Throttle, shift and steering system Forward - Neutral - Reverse
fasteners tightened properly gear operation
Throttle plates open and close Steering operation throughout
completely range
Crankcase oil level Acceleration from idle rpm
Power trim oil level WOT rpm within
specifications (in forward gear)
Sterndrive unit oil level
Power trim operation
Power steering fluid level
Trim tab adjustment
Closed cooling level
Boat handling
Transmission fluid level
AFTER ON WATER TEST
Alternator belt tension
Propeller nut torque
Seawater pickup pump belt
tension
Fuel, oil, coolant, water and fluid
Power steering pump belt tension leaks
Audio warning system operation Oil and fluid levels
Apply Quicksilver Corrosion Guard to
engine package
Page 96 of 96

86302102

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

86302102

Hochgeladen von

Copyright:

Verfügbare Formate

INDEX

The following are registered trademarks of

GASOLINE ENGINES 496 MAG BRAVO

NOTICE to COMMISSIONING DEALER

90-863021002 JANUARY 2001 Printed in U.S.A. -  2001, Mercury Marine Page 1 of 96

Bravo Three Notice: Trim-In Limit Pin Insert

496 MAG And 496 MAG HO Application Recommendations

Latham Marine, Inc.

Mayfair Marine Machine

Multiple Sterndrive Steering Tie Bar Arrangements

INTERNAL TIE BAR ONLY

INTERNAL AND EXTERNAL TIE BAR

EXTERNAL POWER STEERING

EXTERNAL POWER STEERING WITH LOW EXTERNAL TIE BAR

Attn: Parts Department

Outside of U.S.A., order through Distribution Center, or Distributor.

Lubricants / Sealants / Adhesives

Serial Number Decal Placement

a - Specification/Serial Number Decal

a - Painted Boat Transom

a - Transom Thickness - 2 In. (51mm) Minimum To 2-1/4 In.(57mm) Maximum

COMBUSTION AIR REQUIREMENTS

Combustion Air Requirements (Per Engine)

Maximum Pressure Differential at WOT

Model “c” = “a” Minus “b”

Continuous Downward Slope From Horizontal

Minimum Exhaust Outlet Hose Size

• Exhaust hoses must be secured at each connection with 2 hose clamps.

THROUGH THE TRANSOM EXHAUST MODELS

MAGNUM BRAVO MODEL EXHAUST RECOMMENDATION

Typical Waterlift Muffler Exhaust System

CAN Be Used With: CANNOT Be Used With:

Fuel Delivery System

Inside Diameter of Fittings and Lines 3/8 in. (10 mm)

SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS

MULTIPLE EFI ENGINE BATTERY PRECAUTIONS

Cable Length Cable Gauge

EFI Electrical System Precautions

Power Trim Control

IMPORTANT: When selecting a propeller consider this additional information, if

Seawater Pickup Hose Inner Diameter 1-1/4 in. (32 mm)

Seawater Strainer Minimum Flow Rate 30 U.S. gal/min. (114 L/min.)

Hot Water Heater

a - Supply Hose Connection

Throttle/Shift Remote Control and Cables

Steering Helm and Cable

a - Quicksilver Ride Guide Steering Cable Self-Locking Coupler Nut (Identified by

STEERING CABLE SPECIFICATIONS

a - Coupler Nut - 7/8 - 14 Unf - 28 Thread

a - Steering Cable Mounting Flange

Finding Crankshaft Vertical Centerline

Locate and mark vertical centerline on transom.

1. Locate and mark boat vertical centerline “a” on transom.

2. Locate and mark crankshaft vertical centerlines “a” on transom.

a - Draw Crankshaft Vertical Centerline Through Desired Mounting Locations

Minimum Distance Between Crankshaft Vertical Centerlines

Finding Crankshaft Horizontal Centerline (X Dimension)

90° TOOL METHOD

1. Construct 90° tool.

a - Dimension From Chart Below

To Lower Drive Unit - Subtract from dimension “a.”

90° TOOL VERTICAL DIMENSION CHART

TAPE MEASURE METHOD

Model Bravo One / Two / Three